Thermal Dynamics CUTMASTER A120 Operating Manual
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Thermal Dynamics CUTMASTER A120 Operating Manual

Automated plasma cutting syst
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A120
operating manual
CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AO
Date: Dec. 7, 2012
Operating Features:
™
Art # A-08955_AB
Manual # 0-4989
380-
460
600
400

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  • Page 1 A120 CutmASteR ™ AutomAted PLASmA CuttING SYStem Art # A-08955_AB operating manual Rev. AO Date: Dec. 7, 2012 Manual # 0-4989 Operating Features: 380-...
  • Page 2 426-1888, or visit us on the web at www.thermal-dynamics.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern.
  • Page 3 WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™...
  • Page 4 This Page Intentionally Blank...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ...................1-1 1.01 Notes, Cautions and Warnings ..................1-1 1.02 Important Safety Precautions ..................1-1 1.03 Publications ........................1-2 1.04 Note, Attention et Avertissement ..................1-3 1.05 Precautions De Securite Importantes ................1-3 1.06 Documents De Reference ....................1-5 1.07 Declaration of Conformity .....................1-6 1.08 Statement of Warranty ....................1-7...
  • Page 6 TABLE OF CONTENTS PATENT INFORMATION .......................4T-58 SECTION 5 SYSTEM: SERVICE .......................5-1 5.01 General Maintenance ....................5-1 5.02 Maintenance Schedule ....................5-2 5.03 Common Faults ......................5-2 5.04 Fault Indicator .......................5-3 5.05 Basic Troubleshooting Guide ..................5-4 5.06 Power Supply Basic Parts Replacement ..............5-6 SECTION 5 TORCH: SERVICE .......................5T-1 5T.01 General Maintenance ....................5T-1 5T.02...

  • Page 7: Section 1: General Information

    CUTMASTER A120 SECTION 1: • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. GENERAL INFORMATION • Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. • The kinds of fumes and gases from the plasma arc depend on 1.01 Notes, Cautions and Warnings the kind of metal being used, coatings on the metal, and the Throughout this manual, notes, cautions, and warnings are used to different processes.

  • Page 8: Publications

    CUTMASTER A120 • Ventilate all flammable or explosive vapors from the workplace. 1.03 Publications • Do not cut or weld on containers that may have held combus- Refer to the following standards or their latest revisions for more tibles. information: • Provide a fire watch when working in an area where fire hazards 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, may exist. obtainable from the Superintendent of Documents, U.S.

  • Page 9: Note, Attention Et Avertissement

    CUTMASTER A120 1.04 Note, Attention et Avertissement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont FUMÉE et GAZ utilisés pour mettre en relief des informations à caractère important. La fumée et les gaz produits par le procédé de jet de plasma peuvent Ces mises en relief sont classifiées comme suit : présenter des risques et des dangers de santé.
  • Page 10 CUTMASTER A120 Nuance Minimum Nuance Suggerée • Montez et maintenez le matériel conformément au Code électrique Courant Arc Protective Numéro Numéro national des Etats-Unis. (Voir la page 5, article 9.) Moins de 300* • Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation. 300 - 400* • Lisez et respectez toutes les consignes du Manuel de consignes. 400 - 800* * Ces valeurs s’appliquent ou l’arc actuel est observé...

  • Page 11: Documents De Reference

    CUTMASTER A120 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT été faites à celles-ci pour de plus amples renseignements : RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de...

  • Page 12: Declaration Of Conformity

    This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director Victor Technologies International, Inc.

  • Page 13: Statement Of Warranty

    This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose. Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation...
  • Page 14 CUTMASTER A120 This Page Intentionally Blank GENERAL INFORMATION Manual 0-4989...

  • Page 15: Section 2 System: Introduction

    Acrobat PDF format INTRODUCTION by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the 2.01 How To Use This Manual Literature link: This Owner’s Manual applies to just specification http://www.thermal-dynamics.com...

  • Page 16: Power Supply Specifications

    Output Current 30 - 120 Amps, Continuously Adjustable Power Supply Gas Filtering Ability Particulates to 5 Microns CutMaster A120 Power Supply Duty Cycle * Ambient Temperature Duty Cycle Ratings @ 40° C (104° F) Operating Range 0° - 50° C...

  • Page 17: Input Wiring Specifications

    CUTMASTER A120 2.05 Input Wiring Specifications CutMaster A120 Power Supply Input Cable Wiring Requirements Input Freq Power Suggested Sizes voltage Input Volts I max I eff Fuse Flexible Cord Flexible Cord (amps) (Min. AWG) (Min. mm 1 Phase 208 26.2...

  • Page 18: Power Supply Features

    CUTMASTER A120 2.06 Power Supply Features Art # A-08460 Control Panel Torch Leads Receptacle Mounting Rails Work Cable and Clamp Automation Interface Cable Port Input Power Selection Filter Assembly Gas Inlet Port Input Power Cord Art # A-08461 INTRODUCTION Manual 0-4989...

  • Page 19: Section 2 Torch: Introduction

    CUTMASTER A120 SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Automation Torch, Model 2T.01 Scope of Manual The standard automation torch has a position- ing tube with rack & pinch block assembly and This manual contains descriptions, operating a solenoid valve.

  • Page 20: 04 Options And Accessories

    CUTMASTER A120 C. Torch Parts H. Direct Contact Hazard Starter Cartridge, Electrode, Tip, Shield Cup For standoff tip the recommended standoff is 3/16 inches / 4.7 mm. D. Parts - In - Place (PIP) 2T.04 Options And Accessories Torch Head has built - in switch For options and accessories, see section 6.
  • Page 21 CUTMASTER A120 E. Parts - In - Place (PIP) By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration The torch includes a 'Parts - In - Place' (PIP) circuit. of heat to a small area. The stiff, constricted plasma When the shield cup is properly installed, it closes arc is shown in Zone C.
  • Page 22 CUTMASTER A120 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4989...

  • Page 23: Section 3 System: Installation

    CUTMASTER A120 mounting the power supply. Choose one SECTION 3 SYSTEM: that allows for free movement of torch INSTALLATION leads, complies with ventilation per section 2.04 and provides a safe firm surface where the unit can be secured. 3.01 Unpacking 2.

  • Page 24: Primary Input Power Connections

    CUTMASTER A120 3.05 Primary Input Power Connections Upper Screws Lower CAUTION Screws Check your power source for correct voltage before plugging in or connecting the unit. Slots Check the Voltage Selector at the rear of the unit for correct setting before plugging in...
  • Page 25 CUTMASTER A120 D. Quick Guide to Phase Wiring The following illustration and directions are for CAUTION changing phase of the power supply. The primary power source and power cable must conform to local electrical code and the Input Power Cable Connections recommended circuit protection and wiring Single-Phase (1ø) and Jumper Settings...

  • Page 26: Gas Connections

    CUTMASTER A120 Filter Assembly CAUTION Inlet Port The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2). Hose Clamp 6. Connect the wires as follows.
  • Page 27 CUTMASTER A120 Installing Optional Two - Stage Air Filter Kit Filter Assembly This optional two - stage air line filter is also for use on compressed air shop systems. Filter Inlet Port removes moisture and contaminants to at least 5 microns.
  • Page 28 CUTMASTER A120 Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance proce- dures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material.

  • Page 29: Section 3 Torch: Installation

    2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- position. ply. Connect only the Thermal Dynamics model 3. Place a welding filter lens in front of the SL100SV / Automation, SL100 / Mechanical torch and turn ON the air.
  • Page 30 CUTMASTER A120 3T.03 Setting Up Automation or Machine Torch NOTE An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine or automation torch. WARNING Disconnect primary power at the source before disassembling the torch or torch leads.

  • Page 31: Section 4 System: Operation

    CUTMASTER A120 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

  • Page 32: Preparations For Operation

    Check that the torch is properly connected. Only exists and for a ten (10) minute period once Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torches may be connected to this the condition is cleared.
  • Page 33 CUTMASTER A120 Cutting Operation STANDOFF When the torch leaves the workpiece during cutting CutMaster A120 Gas Pressure Settings operations with the Function Control Knob in the SL100 RUN position, there is a brief delay in restarting Leads SL100 (Mechanized Torch) the pilot arc.
  • Page 34 CUTMASTER A120 This Page Intentionally Blank OPERATION Manual 0-4989...

  • Page 35: Section 4 Torch: Operation

    CUTMASTER A120 SECTION 4 TORCH: For optimum smooth surface quality, the travel speed should be adjusted so that only the lead- OPERATION ing edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be 4T.01 Machine and Automated Torch...

  • Page 36: 02 Automation Torch Parts Selection

    CUTMASTER A120 4T.02 Automation Torch Parts Torch Head Art # A-04173_AB Selection Electrode Check the torch for proper consumable parts. The parts supplied in the torch may not be cor- rect for the operator’s chosen amperage level. Start Cartridge The torch parts must correspond with the type of operation.

  • Page 37: 04 Cut Quality

    CUTMASTER A120 Change the torch parts for a different operation as 4T.04 Cut Quality follows: NOTE WARNING Cut quality depends heavily on setup and parameters such as torch standoff, align- Disconnect primary power at the source before assembling or disassembling torch parts, or ment with the workpiece, cutting speed, gas torch and leads assemblies.

  • Page 38: 05 General Cutting Information

    CUTMASTER A120 Bottom Dross Buildup Edge Starting Molten material which is not blown out of the For edge starts, hold the torch perpendicular to cut area and resolidifies on the plate. Excessive the workpiece with the front of the tip near (not...

  • Page 39: 06 Hand Torch Operation

    CUTMASTER A120 3. Hold the torch away from your body. 4T.06 Hand Torch Operation 4. Slide the trigger release toward the back Standoff Cutting With Hand Torch of the torch handle while simultaneously squeezing the trigger. The pilot arc will NOTE start.
  • Page 40 CUTMASTER A120 8. For a consistent standoff height from the 2. The torch can be comfortably held in one workpiece, install the standoff guide by hand or steadied with two hands. Position sliding it onto the torch shield cup. Install...
  • Page 41 CUTMASTER A120 9. Follow normal recommended cutting 6. Bring the torch within transfer distance to practices as provided in the power supply the work. The main arc will transfer to the operator's manual. work, and the pilot arc will shut OFF.

  • Page 42: 07 Gouging

    CUTMASTER A120 4T.07 Gouging Lead Angle The angle between the torch and workpiece depends on the output current setting and torch WARNING travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten Be sure the operator is equipped with proper...
  • Page 43 CUTMASTER A120 This Page Intentionally Blank Manual 0-4989 4T-9 OPERATION...

  • Page 44: 08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    CutMaster a120 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208...
  • Page 45 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2920 1810 1470 4.8 (7.6m) 1345 5.2 (15.2m)
  • Page 46 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 47 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 48 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • Page 49 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7620 3500 2350 4.8 (7.6m) 2170 1740 5.2 (15.2m)
  • Page 50 CutMaster a120 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 51 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7540 7015 0.10 4570 0.10 3650 0.20...
  • Page 52 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 53 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 10890 0.00 7560 0.10 4365 0.10 2865 0.20...
  • Page 54 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • Page 55 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 17010 0.00 7680 0.10 6410 0.10 5230 0.20...
  • Page 56 CutMaster a120 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 57 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8915 0.00 7415 0.10 5915 0.10 4095 0.30...
  • Page 58 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 59 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 9020 0.00 8380 0.00 7730 0.10 5865 0.20...
  • Page 60 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • Page 61 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 8890 8420 0.00 0.10 7170 5710 0.20...
  • Page 62 CutMaster a120 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8213 9-8218 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 63 CutMaster a120 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-821 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 64 CutMaster a120 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 65 CutMaster a120 This Page Intentionally Blank Manual 0-4989 4T-31 OPERATION...
  • Page 66 CutMaster a120 Mild Steel 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 67 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2950 10.0 2100 12.0 1860 5.5 (7.6m)
  • Page 68 CutMaster a120 Stainless Steel 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • Page 69 CutMaster a120 Aluminum 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...

  • Page 70: 09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip

    CutMaster a120 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277...
  • Page 71 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 72 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 73 CutMaster a120 This Page Intentionally Blank Manual 0-4989 4T-39 OPERATION...
  • Page 74 CutMaster a120 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 75 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 6804 5942 0.10 5080 0.10 3316 0.20...
  • Page 76 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 77 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4590 0.00 3925 0.10 3285 0.10 1985 0.20...
  • Page 78 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 79 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...
  • Page 80 CutMaster a120 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 81 CutMaster a120 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 7895 6395 0.10 4895 0.10 4025 0.30...
  • Page 82 CutMaster a120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 83 CutMaster a120 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9410 8120 0.00 6830 0.10 5635 0.20...
  • Page 84 CutMaster a120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 85 CutMaster a120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9020 0.00 7595 0.10 6165 0.20...
  • Page 86 CutMaster a120 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 87 CutMaster a120 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 88 CutMaster a120 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 89 CutMaster a120 Mild Steel 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 90 CutMaster a120 Stainless Steel 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 91 CutMaster a120 Aluminum 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...

  • Page 92: Patent Information

    CUTMASTER A120 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8232 Electrode US Pat No(s) 6163008; 6987238...
  • Page 93 CUTMASTER A120 Catalog # Description Patent(s) 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:...
  • Page 94 CUTMASTER A120 This Page Intentionally Blank OPERATION 4T-60 Manual 0-4989...

  • Page 95: Section 5 System: Service

    CUTMASTER A120 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed...

  • Page 96: Maintenance Schedule

    3. Metal too thick. ment. 4. Worn torch parts 5. Cutting current too low. Daily Operational Checks or Every Six Cutting 6. Non - Genuine Thermal Dynamics Hours: parts used 7. Incorrect gas pressure Check torch consumable parts, replace if damaged or worn.

  • Page 97: Fault Indicator

    CUTMASTER A120 5.04 Fault Indicator At initial power up, two lights will temporarily illu- minate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.

  • Page 98: Basic Troubleshooting Guide

    CUTMASTER A120 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause...
  • Page 99 CUTMASTER A120 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install Gas flow is cycling cartridge missing. missing parts. ON and OFF. 3. Torch start cartridge is stuck.

  • Page 100: Power Supply Basic Parts Replacement

    CUTMASTER A120 5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced.
  • Page 101 CUTMASTER A120 Optional Single-Stage Filter Element 5. Remove the fitting from the filter element as- sembly by inserting a 6 mm hex wrench into Replacement the internal hex fitting and turning it counter These instructions apply to power supplies where the clock-wise (left).
  • Page 102 CUTMASTER A120 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unac- ceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

  • Page 103: Section 5 Torch: Service

    CUTMASTER A120 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System" for com- mon and fault indicator descriptions. Threads Lower O-Ring Cleaning Torch...

  • Page 104: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER A120 5T.02 Inspection and Replacement 4. Remove the tip. Check for excessive wear (indi- cated by an elongated or oversized orifice). Clean of Consumable Torch Parts or replace the tip if necessary. Good Tip Worn Tip WARNING Disconnect primary power to the system be- fore disassembling the torch or torch leads.

  • Page 105: Section 6: Parts Lists

    The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # CutMaster A120 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with 208/230 single phase input power cable and plug 3-1734-1...

  • Page 106: Replacement Power Supply Parts

    CUTMASTER A120 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 9-0191 Input Power Cord for 400 V Power Supply 9-0216 6.05 Options and Accessories...
  • Page 107 CUTMASTER A120 This Page Intentionally Blank Manual 0-4989 PARTS LIST...

  • Page 108: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    CUTMASTER A120 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O-Ring 8-3487 Small O-Ring 8-3486 PIP Switch Kit 9-7036...
  • Page 109 CUTMASTER A120 Art # A-07113 Manual 0-4989 PARTS LIST...

  • Page 110: Torch Consumable Parts (Sl100)

    CUTMASTER A120 6.07 Torch Consumable Parts (SL100) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208...

  • Page 111: Replacement Parts For Hand Torch

    CUTMASTER A120 6.08 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219 Large O-Ring 8-3487 Small O-Ring...
  • Page 112 CUTMASTER A120 This Page Intentionally Blank PARTS LIST Manual 0-4989...

  • Page 113: Appendix 1: Sequence Of Operation (Block Diagram

    CUTMASTER A120 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN...

  • Page 114: Appendix 2: Data Tag Information

    CUTMASTER A120 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and M odel : Revision Level, Serial Number and Production Code Dat e of M f r : Made in USA Type of Power...

  • Page 115: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER A120 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green /...

  • Page 116: Appendix 4: Torch Connection Diagrams

    CUTMASTER A120 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Receptacle Power Connector Torch Torch Supply...
  • Page 117 CUTMASTER A120 This Page Intentionally Blank Manual 0-4989 APPENDIX...

  • Page 118: Appendix 5: System Schematic, 208/460V Units

    CUTMASTER A120 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2...
  • Page 119 Date: Date: Date: ECO B1357 RWH 03/31/09 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. JANUARY 31, 2008 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 120: Appendix 6: System Schematic, 400/600V Units

    CUTMASTER A120 APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2...
  • Page 121 ECO B1611 05/05/09 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. MARCH 30, 2009 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 122: Appendix 7: Raw Arc Voltage

    CUTMASTER A120 APPENDIX 7: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes.
  • Page 123 CUTMASTER A120 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control . Manual 0-4989 A-11 APPENDIX...
  • Page 124 CUTMASTER A120 This Page Intentionally Blank APPENDIX A-12 Manual 0-4989...
  • Page 125 CUTMASTER A120 This Page Intentionally Blank Manual 0-4989 A-13 APPENDIX...

  • Page 126: Appendix 8: Publication History

    CutMaster a120 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) June 30, 2008 Manual released. Sept. 19, 2008 Added CE information Per ECOB. Jan. 27, 2009 Updated art in section 3 to show all the information for the two stage filter per ECOB1248.
  • Page 128 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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